Method and apparatus for a mobile robotic unit

ABSTRACT

A method for managing inventory carriers using mobile robotic units (MRUs) in a pod that is configured to receive online orders at a replenishment station for pickup by customers at a delivery station includes receiving, by an MRU, instructions that identify a first inventory carrier, moving the MRU to a location of the identified inventory carrier, and using the MRU to transport the identified inventory carrier to the replenishment station for pickup by a delivery vehicle.

RELATED APPLICATIONS

In full or in part, this application describes the same apparatus and method as presented in U.S. provisional patent application No. 62/336,904, filed on May 16, 2016, and claims priority thereto. The subject matter of which is hereby incorporated herein by reference and is made a part hereof in its entirety.

FIELD

The present disclosure is directed to systems and methods for delivery for online orders. Specifically, the disclosure is directed to automated material handling systems for delivering online orders to customers.

BACKGROUND

Conventional online order delivery systems present in the current grocery industry face significant challenges in responding to requests for timely, accurate and smooth delivery, while keeping delivery costs low.

A major portion of online orders is being home delivered. But customers are not always available at home to receive the delivery and in general there is a growing reluctance to paying the additional fees requested from the retailers to cover the additional costs to deliver.

Another method of delivery for online orders is conducting the delivery at click-&-collect (or drive through) units which are in store, adjacent to the store and in some scenarios, away from the existing retailer's stores. In such scenarios, the retailer transfers a number of orders to the unit where operators place the orders on racks using barcode based handling systems. The customer is then required to visit the unit within a predetermined time slot and an operator following a concrete procedure delivers the ordered goods. Unfortunately, for the retailers using this method, the final cost is greater than that of the conventional business model where the customer is visiting the store and collecting the items from the shelves by himself. This higher cost combined with the established customers' attitude where they want to pay store prices for online purchases and the razor thin margin of this industry results in making online orders and deliveries non-profitable for grocery retailers.

An additional drawback related with the manually operated click-&-collect systems is the difficulty to handle returns, i.e. the process that a customer needs to follow when returning one or more products purchased via an online order is much more complicated.

Another option for delivery of online orders is the use of lockers. The customers, upon placing the online order, receive a delivery code designating the place and the time slot to fetch the ordered items. Then, the customer visits the designated locker during the predefined time slot and picks up his/her order. This method has a number of advantages compared to the other methods in use. However, locker systems present issues such as low storage capacity and relatively high cost of replenishment.

Accordingly, there is a need for a fully automated pod, comprising mobile robotic units which help carry out the replenishment process and delivery process of orders placed online by customers.

SUMMARY

As described herein, a method for managing inventory carriers using mobile robotic units (MRUs) in a pod that is configured to receive online orders at a replenishment station for pickup by customers at a delivery station includes receiving, by an MRU, instructions that identify a first inventory carrier, moving the MRU to a location of the identified inventory carrier, and using the MRU to transport the identified inventory carrier to the replenishment station for pickup by a delivery vehicle.

Further as described herein, the method includes determining slot availability within the pod, and delivering additional inventory carriers to the pod based on slot availability.

Further as described herein, in accordance with the method, one or more of the additional inventory carriers is laden with one or more containers containing an online order.

Further as described herein, delivering additional inventory carriers includes includes performing the steps of the method multiple times followed by delivering multiple additional inventory carriers.

Further as described herein, delivering additional inventory carriers includes alternately performing the steps of the method and delivering additional inventory carriers.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, exemplify the embodiments of the present invention and, together with the description, serve to explain and illustrate principles of the invention. The drawings are intended to illustrate major features of the exemplary embodiments in a diagrammatic manner. The drawings are not intended to depict every feature of actual embodiments nor relative dimensions of the depicted elements, and are not drawn to scale.

FIG. 1 illustrates the replenishment station 1, according to an exemplary embodiment.

FIG. 2 illustrates a wire cage structure 2 of an empty inventory carrier 3, according to an exemplary embodiment.

FIG. 3 illustrates an inventory carrier 3 with containers 39, according to an exemplary embodiment.

FIG. 4 illustrates an inventory carrier 3 placed on a carrier base 5 at a replenishment station 1. Underneath the carrier base 5 is a Mobile Robotic Unit (MRU) 10, according to an exemplary embodiment.

FIG. 5 illustrates an inventory carrier 3 loaded with containers 39 at the replenishment hatch 23, according to an exemplary embodiment.

FIGS. 6 and 7 illustrate a carrier base 5. On the top sides of the carrier base the two guiding rails 7 for the inventory carrier wheels 3 are shown, according to an exemplary embodiment.

FIG. 8 illustrate a mini-load system 8 that is capable to handling containers, according to an exemplary embodiment.

FIG. 9 illustrates a mini load system 8 with two inventory carriers 3. Mini-load system 8 is transferring containers 39 from one inventory carrier 3 to the other, according to an exemplary embodiment.

FIG. 10 illustrates a mini-load system 8 fetching containers 39 from an inventory carrier 3 and loading them onto a delivery carrier 9, according to an exemplary embodiment.

FIGS. 11 and 12 illustrate a delivery carrier 9 propelled by an MRU 10 to a delivery hatch 24—Drawers 12 are shown wide open and ready for the customer to pick up the items, according to an exemplary embodiment.

FIG. 13 illustrates the customer side of the delivery hatch 24 with the control panel 13 and the drawers 12 open while a customer is picking up her online order's items, according to an exemplary embodiment.

FIG. 14 illustrates the electromagnets 15 that lock the drawers and the spring 16 that pushes the drawer open when electromagnets are deactivated, according to an exemplary embodiment.

FIG. 15 illustrates a dynamic roller conveyor 17 for loading containers into a home delivery vehicle 18, according to an exemplary embodiment.

FIG. 16 illustrates a home delivery vehicle 18 equipped for container loading, according to an exemplary embodiment.

FIG. 17 illustrates a Hub and Spokes arrangement, according to an exemplary embodiment.

FIG. 18 depicts a floor plan of replenishment pod 35, according to an exemplary embodiment.

FIG. 19 depicts a legend for the pod replenishment processes described in FIGS. 20-26.

FIG. 20 depicts a flowchart describing the process to start replenishment, according to an exemplary embodiment.

FIG. 21 depicts a flowchart describing the inbound process, according to an exemplary embodiment.

FIGS. 22A and 22B depict a flowchart describing the wire-frame/inventory carrier inbound process, according to an exemplary embodiment.

FIG. 23 depicts a flowchart describing the outbound process, according to an exemplary embodiment.

FIG. 24 depicts a flowchart describing the wire-frame/inventory carrier outbound process, according to an exemplary embodiment.

FIG. 25 depicts a flowchart describing the process to cancel the inbound or outbound procedure, according to an exemplary embodiment.

FIG. 26 depicts a flowchart describing the door logic, according to an exemplary embodiment.

FIG. 27 depicts a legend for the order delivery processes described in FIGS. 28-33, according to an exemplary embodiment.

FIGS. 28A and 28B depict a flowchart describing the customer sign-in process, according to an exemplary embodiment.

FIG. 29 depicts a flowchart describing the order delivery process, according to an exemplary embodiment.

FIG. 30 depicts a flowchart describing the process of pick-up per delivery carrier, according to an exemplary embodiment.

FIG. 31 depicts a flowchart describing the idle timeout process, according to an exemplary embodiment.

FIG. 32 depicts a flowchart describing the process of cancellation of delivery, according to an exemplary embodiment.

FIG. 33 depicts a flowchart describing the drawer logic, according to an exemplary embodiment.

In the drawings, the same reference numbers and any acronyms identify elements or acts with the same or similar structure or functionality for ease of understanding and convenience. To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the Figure number in which that element is first introduced.

The present disclosure is susceptible of various modifications and alternative forms, and some representative embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the inventive aspects are not limited to the particular forms illustrated in the drawings. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.

DETAILED DESCRIPTION

Various examples of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these examples. One skilled in the relevant art will understand, however, that the invention may be practiced without many of these details. Likewise, one skilled in the relevant art will also understand that the invention can include many other obvious features not described in detail herein. Additionally, some well-known structures or functions may not be shown or described in detail below, so as to avoid unnecessarily obscuring the relevant description.

The terminology used below is to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific examples of the invention. Indeed, certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

Similarly, while operations may be depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

In accordance with certain embodiments, the disadvantages and/or problems associated with existing conventional online order delivery systems may substantially be reduced or eliminated. With reference to FIG. 18, an order that is placed by a customer, for example online, is delivered from a fulfillment center (not shown) to a pod 35, and the customer then picks up the order at the pod. The handling of the order at the pod 35, from its receipt at the replenishment station 1 to its pickup by the customer at the delivery station 45, is automated for streamlined, efficient operation that is seamless to the customer and cost-effective to the retailer. For example, one or more containers 39, on an inventory carrier 3, are delivered, for example by truck (not shown), from the fulfillment center to the pod 35. The customer, at a convenient time, is then able to pick up the order at the delivery station 45 of the pod 35. By stacking the containers 39, using an inventory carrier 3 having a wire frame 2 (FIG. 2), and automatically handling and transporting the contents of the order within the pod for delivery, pickup, storage, handling, loading and unloading, the container handling and shipping efficiency between the retailer and customer is scaled up by a factor of 15×-30× depending on the number of containers involved in the order.

In accordance with certain embodiments, and with reference to FIGS. 4, 5, and 7, delivering an inventory carrier 3, consisting of wire frame 2 and optionally laden with containers 39, to a pod 35, includes transporting the inventory carrier 3 to a designated replenishment hatch 23 of a replenishment station 23. The inventory carrier is placed on a carrier base 5 (FIGS. 5-7). Two special rails 7 (FIG. 6) are attached on the sides of the upper surface of the carrier base 5 to guide wheels 37 (FIGS. 2 and 7) of inventory carrier 3 into the correct position and lock them there so that the inventory carrier 3 remains securely coupled with the carrier base 5 while being transferred by a mobile robotic unit (MRU) 10 within the pod 35, for example for placement at the proper temperature room within the pod 35 (see FIG. 18). As shown in the plan view of FIG. 18, in pod 35, there are three temperature zone areas: one for non-perishable items 29, a second one 30 for fresh items, and a third one 31 for frozen items. Also shown in FIG. 18 are replenishment hatch(es) 23 through which the order is delivered from the fulfillment center to the pod 35, and delivery hatch(es) 24 from which a customer picks up the order. Track 21 and unloading platform 22 for assisting delivery to the pod 35 are also shown. A chilled room automatic door 32 and a frozen room automatic door 33 are provided.

In certain embodiments, and with reference to FIGS. 11-13, a customer is identified using one of many available identification methods at the delivery station 45, for example using an RFID tag carried by the customer, or using a security code entered by the customer, and so on. An interface for the customer, such as a touch or key panel and screen 13, may be provided at the delivery station, to aid in identifying and authenticating and otherwise communicating with the customer. Once identified, the customer is given access to his/her order via the delivery hatch 24 of the pod.

In certain embodiments, and with reference to FIGS. 8-13, containers 39 of a specific order are transported to the delivery hatch 24 by way of a mini load system 8. A delivery carrier 9 is provided for the final leg of this transport, to the delivery hatch 24. In such an embodiment, container(s) 39 are delivered to the mini load system 8 by mobile robot unit(s) 10 serving to propel a container-laden inventory carrier 3. The mini-load system then offloads the container(s) 39 from the inventory carrier 3 onto the delivery carrier 9 for the final leg to the delivery hatch 24. The drawers 12 of the delivery hatch 24 are then opened at the appropriate timing so that the customer can retrieve the items. The delivery carrier 9 has a number of racks that each accommodate one or more containers 39. In a certain embodiments the delivery carrier 9 has two racks and each rack accommodates two containers.

Once the pick-up by the customer is complete, the delivery frame 9 is transported by an MRU 10 with the empty containers 39 back to the mini-load station 8. The empty containers 39 are then moved from the delivery frame 9 and placed on an inventory carrier 3, for example to be returned back to the fulfillment center during the next pod replenishment cycle.

Technical advantages of certain embodiments of the present invention include the ability to receive an early message from a customer denoting his/her estimated time of arrival at the pod 35, for example though an email or a text message or other similar method. Then the system sorts out the container(s) 39 involved, and keeps them close to the delivery hatch 24 in such a way as to minimize the time needed to deliver the order when the customer actually arrives at the delivery hatch and claims his/her order.

In certain embodiments, automated home delivery, from the pod 35, is contemplated. For example, the home delivery can involve loading inventory carriers 3 with the appropriate containers 39 into a home delivery vehicle (e.g. truck 18, FIG. 16) for transport to the customer. At the replenishment station 1, using the interface panel 38, the driver identifies the itinerary to be loaded. A first inventory carrier 3 with containers 39 is transported in the pod 35 to the replenishment hatch 23 by an MRU 10, the hatch 23 opens and the operator is instructed to pull out the inventory carrier 3 and load it onto the vehicle. The procedure is repeated likewise until all inventory carriers 3 of the specific itinerary are loaded onto the vehicle.

In certain embodiments, the containers are loaded into a properly-fitted home delivery vehicle 18 which provides for container 39, loading rather than inventory carrier 3 loading, to maximize the loading capacity of the vehicle. In certain embodiments, prior to loading the containers 39 into the vehicle, the containers are relocated from the inventory carriers 3 that they were originally placed at to new inventory carriers so that they are sorted in a Last In-First Out order (LIFO) based on the delivery itinerary details. This procedure is made possible by using the mini load station 8 guided by suitable algorithms. The operator pulls out the first inventory carrier 3 on the loading platform 22 (FIG. 18) and places the containers 39 onto a dynamic roller conveyor 17 (FIG. 15) which is equipped in a specific embodiment with a bar code scanner (not shown), for example fixed at the lower end of the conveyor. Other identification methods may be used as well. As soon as the first container 39 is scanned the operator is guided via a visual “Put to Light” system (not shown) regarding the exact spot to place it in the vehicle, preferable on a rack structure 18 a (FIG. 16). The same steps are followed for the remaining containers 39 and then the process is repeated for each of the remaining inventory carriers 3. In this manner, the containers 39 are finally placed in the delivery vehicle 18 in a LIFO manner, which greatly speeds up the delivery process at the several calls of the itinerary

The details of the several processes relating to pod replenishment and delivery are described below.

Pod Replenishment—

On line orders have been picked and placed into containers 39 at a fulfillment center or dark store or a supermarket (not shown) prior to being sent to a pod 35. Inventory carriers 3 are used to ship the containers to the pod 35.

Upon arrival at the pod 35, the inventory carriers 3 are handled for storage in one of the following separate temperature rooms of the pod, according to an exemplary embodiment:

1) Ambient room 29—All inventory carriers 3 carrying non-perishable items are stored in this area (see FIG. 18—Ambient room 29)

2) Chilled room 30—Inventory carriers 3 carrying fresh items are stored in this area (see FIG. 18—Chilled room 30)

3) Frozen room 31—inventory carriers 3 carrying frozen items are stored in this area (see FIG. 18—Frozen room 31)

Start Replenishment (FIG. 20)—

There are a number of scenarios regarding how exactly the inventory carriers 3 should be fed into the pod 35. The choice of the proper scenario depends on the inventory carrier capacity of the pod, in terms of “slots” available in the pod to accommodate the carriers, and the available hatches 23 at the time of replenishment. The control panel 38 at the replenishment station 1 displays two software button options: Inbound and Outbound, according to an exemplary embodiment.

Scenario 1: There are enough available hatches 23 and slots for all the inbound inventory carriers 3 of the specific shipment. All the inbound inventory carriers 35 will be fed into the pod 35 prior to retrieval of outbound depleted inventory carriers 3 (those carrying empty containers 39), slated for return to the fulfillment center.

Scenario 2: There are a number of available hatches 23 and slots, but this number is smaller than the number of inbound inventory carriers 3 to be fed into the pod 35. A number of inbound inventory carriers 3 will be fed in the available hatches 23; then a number of outbound (e.g. depleted) inventory carriers 3 will be pulled out. This intermittent process will go on up to the point when handling of all inbound and outbound inventory carriers has been completed.

Scenario 3: There are no available free slots in the pod 35. A number of outbound inventory carriers 3 will be pulled out; then an equal number of inbound inventory carriers 3 will be fed in. This intermittent process will go on up to the point when handling of all inbound and outbound inventory carriers has been completed.

First assume that Scenario 1 applies and the operator selects “Inbound” to start the replenishment process.

Inbound Process (FIG. 21)—

As shown in the Inbound Process of the Flow Chart of FIG. 21, inventory carriers 3 are fed into the system as follows:

1) The control panel 38 displays at 2110 the message “Available inventory carrier slots in the system” and prompts the operator to activate the “Proceed” button at 2120.

2) Inbound process is on and further steps are shown in the next section.

Inventory Carrier Inbound (FIGS. 22A and 22B)—

An exemplary embodiment of the inventory carrier inbound process incorporates the following:

1) The hatch 23 opens automatically, provided that a carrier base 5 is already placed in position, as determined at 2115. If not, the control panel displays the message “Carrier base is transferred—Please wait” at 2130.

2) Upon opening the door (2132), a new message appears on the control panel: “Place an inventory carrier and press the continue button” at 2134—The operator pushes, at 2136, an inventory carrier 3 on to the carrier base 5 making sure that the wheels are rolling through rail installed on the floor right in front of the entrance though to the rail guides 7 on the top of the carrier base 5. The front wheels of the inventory carrier 3 are eventually securely fastened into a cavity at the end of the rail course. This ends up to be a very tight coupling between the carrier base 5 and the wire-frame 2 of the carrier itself so that these two remain securely coupled so that an MRU 10 can safely move them within the pod 35. Other means of securely fastening the carrier and base together are also envisioned.

3) The operator presses the “Continue” button.

4) The RH door [1] closes at 2138.

5) The container validation process starts, and at 2139 a validation in progress message is displayed. By using image capture technology and a system of picturing devices (in one embodiment cameras placed on both sides of the entrance hatch 23) the system scans the containers 39 at 2142, by checking barcodes to verify that the correct containers are placed on the inventory carrier 3.

6) Upon successful verification the inventory carrier 3 is transferred by an MRU 10 to a proper empty location within the pod area 35—The inbound process for this first inventory carrier 3 is completed successfully and the same procedure is repeated (steps 1 through 6) for all the inbound pending inventory carriers 3.

7) In the case that the verification found unknown container(s) 39 on an inventory carrier 3, the door re-opens and the operator is guided through the control panel 38 to remove the unknown container(s) and repeat the inbound process for that specific inventory carrier 3.

Outbound Process (FIG. 23)—

As analytically shown in the Outbound Process of the Flow Charts (FIG. 23) inventory carriers 3 are pulled out of the pod 35 as follows, according to an exemplary embodiment:

1) The operator activates the outbound process by choosing at 2310 the “Outbound process” button on the control panel 38 during the “Start Replenishment” procedure.

2) A checklist with inventory carriers 3 to be removed from the pod 35 is displayed on the control panel 38 at 2320.

3) The operator checks the list of the inventory carriers 3 and taps the “Continue” button at 2330.

4) Inventory carrier outbound process commences.

Inventory Carrier Outbound (FIG. 24)—

An exemplary embodiment of the inventory carrier outbound process 2400 incorporates the following:

1) The control panel displays at 2410 the message “Inventory carrier transfer—Please wait”.

2) As soon as an inventory carrier 3 has been transferred at the replenishment hatch 23 the hatch opens automatically at 2420.

3) The control panel displays the message “Please remove the inventory carrier and press the continue button” at 2430.

4) Upon completion of Step 3 the door closes and a new cycle starts back from Step 1 above for the next inventory carrier 3 to be removed from the pod 35.

Cancel Inbound/Outbound (FIG. 25)—

In case the operator needs to cancel the ongoing procedure, either it is inbound or outbound, needs to go through the following steps, according to an exemplary embodiment:

1) At any display screen there is available the soft button “Cancel Inbound/Outbound”. To cancel the process operator activates this button at 2510.

2) A confirmation message depicting “Are you sure” is displayed on the control panel at 2520. Operator confirms at 2530.

3) If the replenishment hatch 23 opens and the message “Remove the inventory carrier from the replenishment hatch and tap the continue button” displays on the control panel at 2540.

4) The operator pulls out the inventory carrier and taps continue at 2542.

5) The door closes at 2544 and the procedure (either inbound or outbound) terminates.

Door Logic (FIG. 26)—

The replenishment hatch 23 is either automatically or manually operated following the specific logic displayed in the “Door Logic” flow chart depicted in FIG. 26.

The processes pertaining to the delivery of the online order to the customer are described below with reference to the flowcharts depicted in the drawings. According to an exemplary embodiment of the overall delivery process, a customer arrives within a pre-selected time slot at the pod 35 to receive his/her order through a delivery hatch delivery hatch 24 which consists of the following parts:

1) A control panel 13 (FIG. 13). In a specific embodiment the control panel could feature a touch screen. In another embodiment the control panel could feature a normal screen equipped with hard keys.

2) A fixed structure (FIG. 11) consisting of:

a) A specially designed frame 14 to coupleable to the delivery carrier (FIG. 11 and FIG. 12) carrying the order containers.

b) Two drawers 12 (FIG. 12 and FIG. 13) each one capable to contain a number of containers 39 depending on their sizes. In a specific embodiment each drawer contains two containers.

3) A delivery carrier 9 to carry the order containers 39 and place them into the drawers 12.

The order delivery process contains the following process phases.

Customer Sign-in (FIGS. 28A and 28B)—

Customer is prompted to sign in through the following process, according to an exemplary embodiment:

1) The control panel 13 displays the message a sign in message at 2802.

2) The customer taps the “Receive order” button at 2804. The button might be a software button on the touch screen or a hard button placed in the periphery around the control panel 13.

3) The control panel 13 displays the message “Sign in method selection” at 2806. The customer is prompted to select a method from a list of methods which includes but is not limited to:

3a) NFC (Near Field Communication)

3b) Voucher identification

3c) QR scanning

A number of other identification methods may be used to identify the customer/order to be delivered. An exemplary embodiment of the identification procedure is further shown in details on “Customer sign-in” flow chart (FIGS. 28A and 28B).

Order Delivery (FIG. 29)—

Depending on the number of containers of the specific order to be delivered, delivery could be concluded in one delivery cycle or more. Each delivery cycle has the following steps, according to an exemplary embodiment:

1) One or more MRUs 10 fetch the wire-frames/inventory carriers 3 that hold containers of the specific order and transfer them at a mini-load station 8. Each Pod 35 contains one or more mini-load stations, the number depending on the throughput capacity needed.

2) Another MRU 10 fetches an empty delivery carrier 9 and transfers it to the same mini-load station 8.

3) The mini-load station 8 fetches a first container 39 of the order to be delivered from an inventory carrier 3 and places it on the delivery carrier 9.

4) Upon completion of the transfer of containers, an MRU 10 moves the delivery carrier 9 to a delivery hatch station 24. Transfer of the containers 39 which are carried on the delivery carrier 9 to the delivery hatch drawers 12 may be achieved in the following manner:

4a) The MRU 10 moves the delivery carrier 9 at a delivery hatch (a pod could feature a number of delivery hatches depending on the delivery throughput capacity needed) 2910.

4b) In certain embodiments each drawer is able to sustain two containers. The MRU 10 eventually propels to the delivery hatch 24 and lowers the delivery carrier 9 with the order containers 39. By doing so the containers are locked onto the bottom of the corresponding drawers 12 as they were found precisely under the boxes prior to lowering the delivery carrier 9.

4c) During container transfer from the delivery carrier 9 onto the drawers 12 the latter are kept firmly in a closed position. This is achieved by a number of electromagnets 15 placed on the DH structure on the back of each drawer 12 which are activated and keep the drawers blocked at the closed position.

4d) Upon completion of the transfer the electromagnets 15 release the drawers. The drawers are pushed to open by springs 16 or other means properly fastened on the back of the drawers 12.

5) The customer fully opens the drawers and picks up his/her order items.

6) As soon as picking up of the items is concluded the customer pushes back the drawers 12 and taps on the button displaying “Pickup completion” at 2920. Then the electromagnets are activated and lock the drawers closed.

7) An MRU 10 removes the delivery carrier from the DH slot (not shown).

Order Pickup Per Delivery Carrier (FIG. 30)—

In case an order consists of more containers than what a delivery carrier 9 can carry then additional delivery cycles may be needed.

Idle Timeout (FIG. 31)—

The exemplary embodiment in which the system handles idle timeouts is displayed in “Idle timeout” flow chart depicted in FIG. 31.

Cancel Delivery (FIG. 32)—

In any stage of the delivery process, the customer is able to abandon the order following the steps shown on “cancel delivery” flow chart depicted in FIG. 32.

Drawers' Logic (FIG. 33)—

The drawers' logic is displayed in “Drawers' logic” flow chart depicted in FIG. 33.

Loading a Home Delivery Vehicle—

Order cut-off time is recognized as a major factor for smooth online customer experience. The closer the cut-off time to the order delivery time slot the smoother the customer experience. This is better served when the online orders are fulfilled as soon as they are received and then sent to a Pod where the final distribution itineraries are managed. A number of pods 35 can be set up around an online order fulfillment center forming a hub and spoke distribution arrangement (FIG. 17). By doing so the function of itineraries shipment formation for the final home distribution is shifted from the Hub to the Spoke, i.e. the Pod. This makes the shipment process a lot simpler and faster and helps shift cut-off time closer to the delivery time slot.

Transportation on the other hand is a major cost factor for home delivery. Conventionally, the industry has used the “Hub and Spoke” systems (FIG. 17) to improve transportation costs. The problem with the state of the art methods in use is that such a distribution scheme rapidly increases shipment managerial problems because all these spokes need on site supervision and shipment management.

The described arrangement is a new business model offering fully unmanned online order sorting and shipment handling by using the following process:

1) Online orders are fulfilled and shipped to the corresponding pod 35 in waves on a FIFO (First In-First Out) basis. Inventory carriers 3 are used to ship the containers 39 with the online orders to the pod 35.

2) Inbound inventory carriers are stored in the pod 35.

3) Upon finalization of a specific home delivery itinerary a list of the containers 39 that need to be sorted out and put in separate inventory carriers 3 is generated.

4) A mini-load unit 8 supported by MRU(s) 10 follow a similar procedure with the one used to deliver an order (see Order Delivery above), loading the containers on a FILO (First In-Last Out) order on inventory carriers 3.

5) Upon arrival of a home delivery vehicle at the pod 35 the driver punches in the replenishment hatch panel control panel 38 the itinerary code number.

6) The system, following a similar procedure with the Outbound Process described above, presents one after the other the inventory carriers 3 carrying the orders to be shipped.

7) In certain embodiments the inventory carriers 3 are loaded into the delivery vehicle. In another embodiment the delivery vehicle 18 is equipped with a special rack structure 18 a (FIG. 16) to store the containers. The containers are stored in a FILO manner through the following steps:

7a) The driver pulls out of the replenishment hatch 23 a first inventory carrier 3 and unloads its containers on the dynamic roller conveyor 17 (FIG. 15). The unloading follows a specific pattern (for example unloading first the top shelf of the inventory carrier, then the next one etc.).

7b) When the first container on the dynamic roller conveyor 17 reaches the unloading front of the dynamic roller conveyor a scanner fixed on the conveyor (not shown) “reads” the container's barcode (not shown).

7c) A “Put to Light” system which is attached at the loading face of the vehicle and is used to guide the driver into which slot in rack 18 a to put the container 39. This way the containers are loaded into the vehicle in a consistent LIFO manner which eventually greatly enhances faster drop off of orders at each and all itinerary's calls.

The disclosure and/or components thereof may be a single device at a single location, or multiple devices at a single, or multiple, locations that are connected together using any appropriate communication protocols over any communication medium such as electric cable, fiber optic cable, or in a wireless manner.

It should also be noted that the disclosure is illustrated and discussed herein as having a plurality of modules which perform particular functions. It should be understood that these modules are merely schematically illustrated based on their function for clarity purposes only, and do not necessary represent specific hardware or software. In this regard, these modules may be hardware and/or software implemented to substantially perform the particular functions discussed. Moreover, the modules may be combined together within the disclosure, or divided into additional modules based on the particular function desired. Thus, the disclosure should not be construed to limit the present invention, but merely be understood to illustrate one example implementation thereof.

The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other. In some implementations, a server transmits data (e.g., an HTML page) to a client device (e.g., for purposes of displaying data to and receiving user input from a user interacting with the client device). Data generated at the client device (e.g., a result of the user interaction) can be received from the client device at the server.

Implementations of the subject matter described in this specification can be implemented in a computing system that includes a back-end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front-end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described in this specification, or any combination of one or more such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), an inter-network (e.g., the Internet), and peer-to-peer networks (e.g., ad hoc peer-to-peer networks).

Implementations of the subject matter and the operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Implementations of the subject matter described in this specification can be implemented as one or more computer programs, i.e., one or more modules of computer program instructions, encoded on computer storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively or in addition, the program instructions can be encoded on an artificially-generated propagated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. A computer storage medium can be, or be included in, a computer-readable storage device, a computer-readable storage substrate, a random or serial access memory array or device, or a combination of one or more of them. Moreover, while a computer storage medium is not a propagated signal, a computer storage medium can be a source or destination of computer program instructions encoded in an artificially-generated propagated signal. The computer storage medium can also be, or be included in, one or more separate physical components or media (e.g., multiple CDs, disks, or other storage devices).

The operations described in this specification can be implemented as operations performed by a “data processing apparatus” on data stored on one or more computer-readable storage devices or received from other sources.

The term “data processing apparatus” encompasses all kinds of apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, a system on a chip, or multiple ones, or combinations, of the foregoing The apparatus can include special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit). The apparatus can also include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, a cross-platform runtime environment, a virtual machine, or a combination of one or more of them. The apparatus and execution environment can realize various different computing model infrastructures, such as web services, distributed computing and grid computing infrastructures.

A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, declarative or procedural languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, object, or other unit suitable for use in a computing environment. A computer program may, but need not, correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.

The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform actions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).

Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for performing actions in accordance with instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, e.g., a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a Global Positioning System (GPS) receiver, or a portable storage device (e.g., a universal serial bus (USB) flash drive), to name just a few. Devices suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

The various methods and techniques described above provide a number of ways to carry out the invention. Of course, it is to be understood that not necessarily all objectives or advantages described can be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the methods can be performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as taught or suggested herein. A variety of alternatives are mentioned herein. It is to be understood that some embodiments specifically include one, another, or several features, while others specifically exclude one, another, or several features, while still others mitigate a particular feature by inclusion of one, another, or several advantageous features.

Furthermore, the skilled artisan will recognize the applicability of various features from different embodiments. Similarly, the various elements, features and steps discussed above, as well as other known equivalents for each such element, feature or step, can be employed in various combinations by one of ordinary skill in this art to perform methods in accordance with the principles described herein. Among the various elements, features, and steps some will be specifically included and others specifically excluded in diverse embodiments.

Particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results.

In closing, it is to be understood that the embodiments of the application disclosed herein are illustrative of the principles of the embodiments of the application. Other modifications that can be employed can be within the scope of the application. Thus, by way of example, but not of limitation, alternative configurations of the embodiments of the application can be utilized in accordance with the teachings herein. Accordingly, embodiments of the present application are not limited to that precisely as shown and described. 

What is claimed is:
 1. A method for vehicle delivery of an order using a pod having a plurality of containers, one or more inventory carriers each having a plurality of wheels to permit motion thereof and each configured to support one or more containers, one or more carrier bases each configured to support an inventory carrier and each including a plurality of rails for entraining wheels of the supported inventory carrier, one or more mobile robotic units (MRUs) each configured to propel an inventory carrier, and one or more mini load stations for manipulating containers, the method comprising: transporting a first inventory carrier supporting a first container containing a first portion of the order from a storage location in the pod to a mini load station; using the mini load station to transfer the first container containing the first portion from the first inventory carrier to a second inventory carrier; transporting the second inventory carrier supporting the first container containing the first portion from the mini load station to a replenishment station of the pod; and loading, from the replenishment station, the first container containing the first portion into a delivery vehicle for delivery to a customer, wherein said transporting includes disposing the inventory carrier on a carrier base having rails in which the wheels of the inventory carrier are locked in place, and propelling the inventory carrier and carrier base using the MRU.
 2. The method of claim 1, wherein loading the first container containing the first portion into a delivery vehicle includes loading the second inventory carrier supporting the first container into the vehicle.
 3. The method of claim 1, wherein the storage location in the pod is in one of multiple temperature zones, in which the first inventory carrier is disposed based on temperature requirements of the first portion of the order.
 4. The method of claim 1, wherein the rails include a cavity for securing a wheel of an inventory carrier in position.
 5. The method of claim 1, wherein the pod is one of multiple pods of a hub-and-spoke arrangement with a fulfillment center, the method further comprising: fulfilling the order at the fulfillment center; delivering the order from the fulfillment center to the replenishment station of the pod, said delivering including: disposing the first portion of the order in the first container and supporting the first container on the first inventory carrier for transport from the fulfillment center to the replenishment station, and rolling the first inventory carrier on the wheels thereof; and transporting the first inventory carrier supporting the first container containing the first portion from the replenishment station to the storage location in the pod by guiding the wheels of the first inventory carrier onto rails provided on a carrier base associated with the first inventory carrier and locking the first inventory carrier in the rails.
 6. The method of claim 5, wherein locking the first inventory carrier in the rails includes dropping a wheel thereof in a cavity in a rail of a carrier base.
 7. The method of claim 5, further comprising: transporting a number of inbound inventory carriers into the pod including guiding wheels of each transported inbound inventory carrier onto rails provided on a carrier base associated with the inbound inventory carrier and locking the inbound inventory carrier in the rails, the inbound inventory carriers including the first inventory carrier supporting the first container containing the first portion of the order, said transporting a number of inbound inventory carriers comprising: determining slot availability within the pod; if the number of available slots within the pod is equal to or exceeds the number of inbound inventory carriers, transporting the number of inbound inventory carriers into the pod; if the number of available slots within the pod is less than the number of inbound inventory carriers, creating additional available slots by removing outbound inventory carriers from the pod, and then transporting inbound inventory carriers into the pod.
 8. The method of claim 7, wherein locking the inbound inventory carrier in the rails includes dropping a wheel thereof in a cavity in a rail of a carrier base.
 9. A pod for delivery of an order from a fulfillment center to a customer, comprising: a plurality of containers; one or more inventory carriers each having a plurality of wheels to permit motion thereof and each configured to support one or more containers; one or more carrier bases each configured to support an inventory carrier, the carrier bases each including a plurality of rails for entraining wheels of the supported inventory carrier; one or more mobile robotic units (MRUs) each configured to propel an inventory carrier; one or more mini load stations for manipulating containers; a memory; a replenishment station; at least one processor configured to execute machine executable code stored in the memory for performance of a procedure comprising: transporting a first inventory carrier supporting a first container containing a first portion of the order from a storage location in the pod to a mini load station; using the mini load station to transfer the first container containing the first portion from the first inventory carrier to a second inventory carrier; transporting the second inventory carrier supporting the first container containing the first portion from the mini load station to a replenishment station of the pod; and loading, from the replenishment station, the first container containing the first portion into a delivery vehicle for delivery to a customer, wherein said transporting includes disposing the inventory carrier on a carrier base having rails in which the wheels of the inventory carrier are locked in place, and propelling the inventory carrier and carrier base using the MRU.
 10. The pod of claim 9, wherein loading the first container containing the first portion into a delivery vehicle includes loading the second inventory carrier supporting the first container into the vehicle.
 11. The pod of claim 9, wherein the storage location in the pod is in one of multiple temperature zones, in which the first inventory carrier is disposed based on temperature requirements of the first portion of the order.
 12. The pod of claim 9, wherein at least one rail of each carrier base includes a cavity for securing a wheel of an inventory carrier in position.
 13. The pod of claim 9, wherein the pod is one of multiple pods of a hub-and-spoke arrangement with a fulfillment center, the procedure further comprising: fulfilling the order at the fulfillment center; delivering the order from the fulfillment center to the replenishment station of the pod, said delivering including: disposing the first portion of the order in the first container and supporting the first container on the first inventory carrier for transport from the fulfillment center to the replenishment station, and rolling the first inventory carrier on the wheels thereof; and transporting the first inventory carrier supporting the first container containing the first portion from the replenishment station to the storage location in the pod by guiding the wheels of the first inventory carrier onto rails provided on a carrier base associated with the first inventory carrier and locking the first inventory carrier in the rails.
 14. The pod of claim 13, the procedure further comprising: transporting a number of inbound inventory carriers into the pod by guiding wheels of each transported inbound inventory carrier onto rails provided on a carrier base associated with the inbound inventory carrier and locking the inbound inventory carrier in the rails, the inbound inventory carriers including the first inventory carrier supporting the first container containing the first portion of the order, said transporting a number of inbound inventory carriers comprising: determining slot availability within the pod; if the number of available slots within the pod is equal to or exceeds the number of inbound inventory carriers, transporting the number of inbound inventory carriers into the pod; if the number of available slots within the pod is less than the number of inbound inventory carriers, creating additional available slots by removing outbound inventory carriers from the pod, and then transporting inbound inventory carriers into the pod. 